INTRODUCTION: The uncomplicated design of these high vacuum gate valves makes servicing easier than on any other gate valve. The valves are welded from custom extrusions of aluminum. These extrusions have a very smooth and bright surface fin- ish which is one of the reasons for the low outgassing and fast pump down of these valves. Dismantling requires no training or practice, and reassembly errors are almost impossible. There is only one way to put any part or assem- bly in place and there are no critical adjustments. With one motion the entire internal mechanism is lifted from the valve while the flanged port section stays bolted in the system. The short body sections make cleaning easier and faster. The centerline body flange makes this possible and reduces maintenance and servicing time to a minimum. The diagram inside shows the rotary seal principle and the no-contact-gate action. The gate (disc) O-ring seals in a motion perpendicular to its seat, without O-ring scuffing. The gate carriage assembly stays securely locked in position at the open or closed position because of the dead centers at the extremes of the 180° arc. The half circle swing of the cam is rapid at mid-way point, slowing to stop at top or bottom. This makes very fast action possible without the hammer effect of a plunger type operator. It is built-in cushioning for the stroke which means negligible wear and a long operating life without maintenance. The valves work equally well in any orientation. It should be determined that the valve and/or adjacent piping of the vacu- um system will be adequately supported when assembled. Make certain the mating flanges are in-line, parallel and the correct distance apart to minimize the strain on the valve body. It is important to remember that the gate seal is on the operator or hub side of the valve on sizes 2" to 8". On sizes 10" and larger the operator is on the opposite, or open side. ™ INSTRUCTION MANUAL VACUUM GATE VALVE WITH ROTARY ACTUATOR WARNING The air supplied to these valves must be free of oil, water and dirt for proper operation. If the air at your facility is not clean and dry you must install filters and traps upstream of the valve. These valves hold vacuum in either direction. However, no gate valve opens easily in a vacuum-to-atmosphere condition with the pressure of atmosphere on the open side,or against the back of the gate. If opening is necessary with a vacuum to atmosphere differential, ensure gate faces upstream (toward atmosphere or higher pressures) or install a means of equalizing pressure prior to actuation. Gate valves will not close easily against atmos- phere if the vacuum side is a large chamber where the inrush of atmosphere may approach very high velocity. MAINTENANCE: The valves do not require any routine maintenance. However, it is necessary to prevent the accumulation of dirt and debris inside the valve and if your vacuum system is extremely dusty or dirty, cleaning the interior of the valve will be required from time to time. When the valve is disassembled for cleaning, it is rec- ommended that the O-rings be replaced. Note that cleaning O-rings with solvents is never recommended, because the sol- vent will be absorbed by the O-ring and will produce high out- gassing for hours or even weeks after such cleaning. If vacuum grease is used on O-rings, it can also cause outgassing and ‘burps’ of gas. Only a thin, almost invisible, coating of grease should be used on O-rings in vacuum systems. Flange O-rings shipped with new valves and O-rings shipped as spare or replacement parts have not been greased prior to shipment. ELECTRO PNEUMATIC (EP) ACTUATORS: The ‘EP’ actuators include a 4-way solenoid valve actuator with 24” leads and are mounted, ready for wiring when valves are ordered for pneumatic operation. The one side of the solenoid bracket (stamped “C”) is normally closed. The other side (stamped “D”) is normally open. The “C” side opens the gate valve; the “D” side closes it. Recommended minimum air pres- sure is 65 psi (4.6 kg/cm 2 ) for valves with 2 inch and 3 inch ANSI flanges (NW-50 to ISO 80). Recommended minimum air pres- sure for valves with 6 inch to 16 inch ANSI flanges (ISO 100 to ISO 400) is 85 psi. (6 kg/cm 2 ). Recommended maximum air pressure for all sizes is 100 psi. (7 kg/cm 2 ). ! WIRING: The preferred method to preclude human error, employs SPST switches as in Fig. 1. Connect two wire leads to source with a SPST toggle switch in either line. When solenoid is energized, valve opens; when solenoid is de-energized, valve closes. Pressure remains in cylinder. FAIL-SAFE: When connected this way, the valve will automati- cally close if power fails. To provide for manual operation during failure, a shut-off and a vent valve must be put in the air line to bleed off high pressure air in the cylinder. You can then operate the valve manually by turning the hex nut on stem with a wrench. With on/off switches, valves will open when power returns unless switched to “off” before power comes on. UUUU FIGURE 1 Select voltage to match the Solenoid e.g. 115, 220, 240 VAC to VDC NOTICE If valve is to be opened with a pressure differential of 50 Torr or more it must be installed with the open side toward the pump & the seal side facing the chamber or furnace (Higher Pressure). Vacuum Furnace Vacuum Pump Seal Side of Valve Facing Furnace This manual also available in PDF file format at: www.vacuumresearch.com
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I NS TR UC O M AL VACUUM GATE VALVE WITH ......Piston & Seal Kit for ‘EP’ Actuators Piston Cup, 2 Shaft & 2 End Cap O-RingsX701204B 45.00 X701204B 45.00 X701404B 45.00 1. Contact
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Transcript
INTRODUCTION:The uncomplicated design of these high vacuum gate valvesmakes servicing easier than on any other gate valve. Thevalves are welded from custom extrusions of aluminum.These extrusions have a very smooth and bright surface fin-ish which is one of the reasons for the low outgassing andfast pump down of these valves. Dismantling requires notraining or practice, and reassembly errors are almostimpossible. There is only one way to put any part or assem-bly in place and there are no critical adjustments. With onemotion the entire internal mechanism is lifted from the valvewhile the flanged port section stays bolted in the system.The short body sections make cleaning easier and faster.The centerline body flange makes this possible and reducesmaintenance and servicing time to a minimum.
The diagram inside shows the rotary seal principle and theno-contact-gate action. The gate (disc) O-ring seals in amotion perpendicular to its seat, without O-ring scuffing. Thegate carriage assembly stays securely locked in position atthe open or closed position because of the dead centers atthe extremes of the 180° arc. The half circle swing of the camis rapid at mid-way point, slowing to stop at top or bottom.This makes very fast action possible without the hammereffect of a plunger type operator. It is built-in cushioning forthe stroke which means negligible wear and a long operatinglife without maintenance.
The valves work equally well in any orientation. It should bedetermined that the valve and/or adjacent piping of the vacu-um system will be adequately supported when assembled.Make certain the mating flanges are in-line, parallel and thecorrect distance apart to minimize the strain on the valvebody. It is important to remember that the gate seal is on theoperator or hub side of the valve on sizes 2" to 8". On sizes10" and larger the operator is on the opposite, or open side.
™ INSTRUCTION MANUALVACUUM GATE VALVE WITH ROTARY ACTUATOR
WARNINGThe air supplied to these valves must be free of oil,water and dirt for proper operation. If the air at yourfacility is not clean and dry you must install filters andtraps upstream of the valve.
These valves hold vacuum in either direction. However, no gatevalve opens easily in a vacuum-to-atmosphere condition with thepressure of atmosphere on the open side,or against the back ofthe gate. If opening is necessary with a vacuum to atmospheredifferential, ensure gate faces upstream (toward atmosphere orhigher pressures) or install a means of equalizing pressure priorto actuation. Gate valves will not close easily against atmos-phere if the vacuum side is a large chamber where the inrush ofatmosphere may approach very high velocity.
MAINTENANCE:The valves do not require any routine maintenance. However, itis necessary to prevent the accumulation of dirt and debrisinside the valve and if your vacuum system is extremely dusty ordirty, cleaning the interior of the valve will be required from timeto time. When the valve is disassembled for cleaning, it is rec-ommended that the O-rings be replaced. Note that cleaningO-rings with solvents is never recommended, because the sol-vent will be absorbed by the O-ring and will produce high out-gassing for hours or even weeks after such cleaning. If vacuumgrease is used on O-rings, it can also cause outgassing and‘burps’ of gas. Only a thin, almost invisible, coating of greaseshould be used on O-rings in vacuum systems. Flange O-ringsshipped with new valves and O-rings shipped as spare orreplacement parts have not been greased prior to shipment.
ELECTRO PNEUMATIC (EP) ACTUATORS:The ‘EP’ actuators include a 4-way solenoid valve actuator with24” leads and are mounted, ready for wiring when valves areordered for pneumatic operation. The one side of the solenoidbracket (stamped “C”) is normally closed. The other side(stamped “D”) is normally open. The “C” side opens the gatevalve; the “D” side closes it. Recommended minimum air pres-sure is 65 psi (4.6 kg/cm2) for valves with 2 inch and 3 inch ANSIflanges (NW-50 to ISO 80). Recommended minimum air pres-sure for valves with 6 inch to 16 inch ANSI flanges (ISO 100 toISO 400) is 85 psi. (6 kg/cm2). Recommended maximum airpressure for all sizes is 100 psi. (7 kg/cm2).
!
WIRING: The preferred method to preclude human error,employs SPST switches as in Fig. 1. Connect two wire leads tosource with a SPST toggle switch in either line. When solenoidis energized, valve opens; when solenoid is de-energized, valvecloses. Pressure remains in cylinder.
FAIL-SAFE: When connected this way, the valve will automati-cally close if power fails. To provide for manual operation duringfailure, a shut-off and a vent valve must be put in the air line tobleed off high pressure air in the cylinder. You can then operatethe valve manually by turning the hex nut on stem with awrench. With on/off switches, valves will open when powerreturns unless switched to “off” before power comes on.
UUUU FIGURE 1
Select voltage to match the Solenoide.g. 115, 220, 240 VAC to VDC
NOTICEIf valve is to be opened with a pressure differential of 50 Torr ormore it must be installed with the open side toward the pump &the seal side facing the chamber or furnace (Higher Pressure).
VacuumFurnace Vacuum
Pump
Seal Side of Valve Facing Furnace
This manual also available in PDF file format at: www.vacuumresearch.com
LPWA-2 & LPWA-3Built Before Sept. 2005
LPWA-2 & LPWA-3Built Sept. 2005 and Later LPWA-4
ISO-80 & ISO-100Any DateCF-6
ISO-160CF-8
Description P/N Price P/N Price P/N PriceClean & Test Valves (freight pre-paid) to Pittsburgh, PA USA $95.00 $95.00 $95.00O-Ringskit BUNA-N, 2 ea. Stem O-Rings, 1 ea. Hub,
Gate & Body (no flange). X810771B 12.00 X810604B 12.00 X810601B 20.00
kit VITON, 2 ea. Stem O-Rings, 1 ea. Hub,Gate & Body (no flange). X810771V 49.00 X810604V 49.00 X810601V 74.00
kit SILICONE, 2 ea. Stem O-Rings, 1 ea.Hub, Gate & Body (no flange). X810771S 49.00 X810604S 49.00 X810601S 74.00
Piston & Seal Kit for ‘EP’ ActuatorsPiston Cup, 2 Shaft & 2 End Cap O-Rings X701204B 45.00 X701204B 45.00 X701404B 45.00
1. Contact VRC for bonnet and port body sections. Rail to rail dimension of 98 mm or 104 mm must be verified on current valve.2. Port section styles available are N1, no neck; N6, neck on seal side; N8, neck on open side; and N5, neck on both sides.
If roughing ports are required specify as R1-NW-16 etc. Roughing port locations are described in Valve Catalog. 3. Gate-Carriage Assembly with O-ring X706103rev1 355.00 X810084 420.00 X706203rev2 450.00
Reverse Gate-Carriage Assembly with O-ring N/A N/A X810057RC 850.003a,b,g
Kit of 4 ea. Carriage Shaft, Roller & LinkAssembly with Bushings & Retaining Ring X806500 98.00 X806500 98.00 X806500 98.00
3c. Gate Rollers - Set of 2 X706102 18.00 X706102 18.00 X706202 35.003d. Carriage Side Rollers - Set of 4 X706108 24.00 X706108 24.00 X706108 24.003e. Spring (set) X706106 9.00 X706206 9.00 X706206 9.003f. Gate Link Shafts - Set of 4 X706110rev1 47.00 X706110rev1 47.00 X706110rev1 47.003h. Roll Pin-Set of 6 (2 Gate, 4 Carriage) X706105 2.00 X706105 2.00 X706205 3.003j. Retaining Ring (gate shafts) - Set/4 X706119 1.00 X706119 1.00 X706119 1.003r. Retain, Ring (carriage shafts) - Set/4 X706119 1.00 X706119 1.00 X706119 1.003y. Gate w/o Shafts, Links, Rollers X02WA116 150.00 X700051 220.00 X04WA116 225.003z. Carriage w/o Shafts, Links, Rollers X02LP117rev1 120.00 X700270 110.00 X04LP117rev1 116.003z. Reverse Carriage w/o Shafts, Links, Rollers X04LPSK446 485.00
Piston & Seal Kit for ‘EP’ ActuatorsPiston Cup, 2 Shaft & 2 End Cap O-Rings X701404B 45.00 X7011004B 60.00 X7011004B 60.00
1. Contact VRC for bonnet and port body sections. Rail to rail dimension of 98 mm or 104 mm must be verified on current valve.2. Port section styles available are N1, no neck; N6, neck on seal side; N8, neck on open side; and N5, neck on both sides.
If roughing ports are required specify as R1-NW-16 etc. Roughing port locations are described in Valve Catalog. 3. Gate-Carriage Assembly with O-ring X706303rev2 530.00 X810439R1 1080.00 X810439 1080.00
3a,b,g
Kit of 4 ea. Carriage Shaft, Roller & LinkAssembly with Bushings & Retaining Ring X806500 98.00 X806502 388.00 X806502 388.00
3c. Gate Rollers - Set of 2 X706302 30.00 X810536 37.00 X810536 37.003d. Carriage Side Rollers - Set of 4 X706108 24.00 X706408 56.00 X706408 56.003e. Spring (set) X706306 17.00 X706406 24.00 X706406 24.003f. Gate Link Shafts - Set of 4 X706110rev1 47.00 X706410rev1 125.00 X706410rev1 125.003h. Roll Pin-Set of 6 (2 Gate, 4 Carriage) X706205rev1 5.00 X706405rev1 5.00 X706405rev1 5.003j. Retaining Ring (gate shafts) - Set/4 X706119 1.00 X706419 1.00 X706419 1.003r. Retain, Ring (carriage shafts) - Set/4 X706119 1.00 X706419 1.00 X706119 1.003y. Gate w/o Shafts, Links, Rollers X406116 230.00 X700044 420.00 X700269 420.003z. Carriage w/o Shafts, Links, Rollers X02LP117rev1 120.00 X708008 356.00 X700285 370.00
Piston & Seal Kit for ‘EP’ ActuatorsPiston Cup, 2 Shaft & 2 End Cap O-Rings X7011004B 60.00 X7011004B 60.00 X810396 160.00
1. Contact VRC for bonnet and port body sections. Rail to rail dimension of 98 mm or 104 mm must be verified on current valve.2. Port section styles available are N1, no neck; N6, neck on seal side; N8, neck on open side; and N5, neck on both sides.
If roughing ports are required specify as R1-NW-16 etc. Roughing port locations are described in Valve Catalog. 3. Gate-Carriage Assembly with O-ring X810507 1495.00 X810777 2165.00 X810624 3910.00
3a,b,g
Kit of 4 ea. Carriage Shaft, Roller & LinkAssembly with Bushings & Retaining Ring X806502 388.00 X810780 552.00 X810397 565.00
3c. Gate Rollers - Set of 2 X810536 37.00 X810778 108.00 X811027 150.003d. Carriage Side Rollers - Set of 4 X706408 56.00 X810779 56.00 X810635 285.003e. Spring (set) X706406 24.00 X706406 24.00 X810636 58.003f. Gate Link Shafts - Set of 4 X706410rev1 125.00 X810781 140.00 X810637 140.003h. Roll Pin-Set of 6 (2 Gate, 4 Carriage) X706405rev1 5.00 X810782 5.00 X810638 155.003j., r Retaining Ring (gate shafts) - Set/4 X706419 1.00 X810783 14.00 X810639 21.003j., r. Retain, Ring (carriage shafts) - Set/4 X706419 1.00 X810784 2.00 X810639 21.003y. Gate w/o Shafts, Links, Rollers X10WA116 420.00 X700599 1200.00 X811680 1350.003z. Carriage w/o Shafts, Links, Rollers X10WA117 655.00 X740059revA 1315.00 X811670 1720.00PCWA Aux. Carriage w/ Shroud, no Rollers or Pins N/A X740063 1050.00 N/APCWA Aux. Carriage Join Pin,Roller, Pin, E-Clip Kit N/A X810840 170.00 N/A
4. Stem-Crank Assembly with Key, Retaining Ring & Nut X706WA416 276.00 X706016 332.00 X810641 675.00
DISASSEMBLY: With valve in open position, remove centerline body flange bolts and lift the bonnet section free. The entireinternal mechanism comes free with this one motion. Then turn the manual lever, or the hex nut above the pinion gear onpneumatic valves, to release the carriage from its locked position. Pull on carriage and it will come out and slide off the crankroller. The flanged section stays bolted in the system unless the gate seat is damaged and needs polishing or machining.When the stem seal area is also to be cleaned or needs new seals, the steps are easy: (1) Take off manual lever or piniongear. (2) Use appropriate snap ring pliers to remove retaining ring 9-r and remove the gland spacer (5-a1) and hub flangescrews. (3) Lift out hub by sliding over stem, which will bring stem seal assembly with it, which can then be lifted out with a fin-ger. (4) The stem crank comes out easily through the centerline flange opening.
ASSEMBLY: Apply a very thin film of vacuum grease to the shaft and: (1) Grasp the stem crank by the roller end, tip the stemto the side, insert in the bonnet flange opening and bring the stem out through the hub opening. (2) Place hub O-ring seal inhub flange and slide hub onto stem while holding stem-crank up to make it easy to insert. (3) Replace and tighten the 1/4-20hub flange screws evenly. (4) While holding the stem crank up with one hand and pushing to the farthest point through thestem housing in the hub, insert the stem seal assembly and be sure of the proper order. Slide over stem first, one O-ring; next,a washer. Then slide the spring over the stem; next a washer, and last, the second O-ring. Make sure this second O-ring isdown over the shoulder on the stem. (5) While still holding up the stem, replace the stem gland spacer (push downward toovercome spring tension). Hold the internal retaining ring 5-C in position and seat it in the modified hub groove using appropri-ate snap ring pliers. (6) Replace manual lever or pinion gear of pneumatic operator with key in its slot. Retaining ring 9-r fitsonto the stem crank. (7) Insert gate seal evenly, and with crank turned to expose its roller, slide carriage slot overroller andretract into bonnet by turning stem counterclockwise (with manual lever or a wrench on pinion head nut). (8) Insert body flangeseal evenly and position the bonnet assembly on the flanged section—Gate toward its seat, with locator pins lined up withholes. (9) Replace and evenly tighten body bolts in centerline flanges.
™
WARNING !A valve wired to automatically close on power failure will also automatically open when power is restored. This reopeningmay be unsafe, and it is recommended that a latching relay be installed so that the valve will not just automatically reopenwhen power is restored, but will remain closed until an operator decides it is safe to reopen.
!
Disconnect electrical & air supply before making any adjustment or repairs.!
CONVERTING FROM MANUAL TO ELECTROPNEUMATIC (EP) OPERATOR: Operators for conversion of manual valvesare factory assembled, aligned and tested before shipment, with piston shafts tight to brackets. Simply tighten brackets tovalve body, with “D” bracket on the “closed” side—to the right as you look at the face of the valve, with centerline flange down.If operators are removed from pneumatic valves, it is generally unnecessary to disassemble them. Leave the shaft tightened tobrackets for easiest reassembly. With cylinder in place, brackets tightened, replace pinion gear parts on the stem in this order:(1) bronze thrust washer, (2) gear washer without key slot, (3) pinion gear, (4) key, (5) gear washer with key slot, (6) hex nut,(7) retaining ring. When placing pinion gear, engage the nearest rack tooth with it, with cylinder at farthest right, toward the“closed” side, and stem and gear key slots aligned. Slight movement of the cylinder may help to align key slots when insertingkey (as in 4). Then proceed with (4) through (7). Secure solenoid actuator to the valve body, with “C” and “D” sides matching“C” and “D” on cylinder. Install air lines and tighten fittings, “C” with “C” and “D” with “D”.
PNEUMATIC OPERATOR ADJUSTMENT:WARNING !
(1) Be sure that the air and power lines are disconnected. (2) This align-ment procedure requires the valve to be completely assembled with gatecarriage installed and the port and bonnet bolted together. (3) If yourvalve is equipped with position indicator switches remove them byremoving the 3 screws that hold the switch bracket to the EP mountingbracket. Remove the protective EP cover so that the actuator cylinderand gears are visible. (4) Loosen the bolts that secure the EP mountingbrackets so the rack and pinion gears (9b & 9c) can be disengaged.After the gears are no longer in contact with each other, use a wrench torotate the hex nut (9j) clockwise to move the gate to the full closed posi-tion (CW). Remove the E clip, hex nut, key, and top guide washer andpull the pinion gear off of the valve stem (Part No. 4). (5) After the pinionis removed, push or tap the EP cylinder (9f) to full closed position (seelabel on cylinder.) Then move the cylinder back toward the open positionby the space of approximately 1/2 or 1 full gear tooth. (6) Now replace
the pinion on the stem and engage it with the rack without moving the cylinder. (7) To ensure that rack and pinion properlyengage without binding or skipping teeth you may tap lightly on the EP brackets to move the rack closer or farther from thepinion. Be sure that all bolts on EP mounting bracket are tight (9d). (8) Re-install the top guide washer, hex nut, key, and E-clip on the stem. (9) Reconnect electrical and air supply. (10) Operate valve and listen for gate locking in closed position.